Weaving method using nonwoven as yarn

ABSTRACT

The present invention provides a weaving method using nonwoven as yarn, which discloses that nonwoven is slit first and then the slit nonwoven is used for weaving. In the weaving, process, yarn with different materials can be added for producing textiles with various functionalities.

FIELD OF THE INVENTION

The present invention relates to a weaving method, and particularly to a weaving method using nonwoven as the yarn.

BACKGROUND OF THE INVENTION

The textile industry is an industry of manufacturing textile goods using a variety of textile raw materials. The main fabrication processes include fiber production, spinning, textile manufacturing, dyeing and printing, finishing, and the final read-to-wear business. The textile industry is an important civil industry of a country. The applications of textile goods include the ready-to-wear business, the upholstery, and the industrial products. The ready-to-wear business includes garments for men, women, and children. The upholstery includes furniture, domestic goods, and domestic decorative cloth, etc. The industrial products include conveyers in factories, filtering cloth, and outdoor tent appliances. In addition, textile goods can be applied to shoemaking and interior decoration of transportations (automobiles or airplanes). Their applications are extremely extensive. Among them, the read-to-wear industry occupies the most significant proportion.

In general, weaving can be classified into knitting and tatting:

-   1. Knitting: A weaving method that uses a single thread of yarn or a     set of threads of yarn to move unidirectionally, and classified into     manual knitting and machine knitting.     -   (a) Manual knitting is performed using two knitting needles         alternately. Loops are distributed uniformly on the knitting         needle. A row of loops is formed with width the same as that of         the textile. When knitting is performed, the row of loops will         connect with next row of loops. In this way, a textile is         knitted.     -   (b) Machine knitting uses a knitting needle in each of the         loops. When knitting, all knitting needles are operating         simultaneously and forming a row of loops. -   2. Tatting: Knitting a thread of warp yarn and a thread of weft yarn     perpendicularly.

The warp yarn is the vertical yarn; the weft yarn is the horizontal yarn. In fact, when the primitives first interwove branches of a tree and grass to form a mat or a basket, the history of weaving was started.

In addition, there exists a textile formed without the spinning process. Firstly, a fiberweb structure is formed by arranging short fibers or long filaments at fixed orientation or randomly. Then, a mechanical, thermal bonding, or chemical method is adopted to fix the fiberweb structure. To put it in a nutshell, the textile is not formed by interweaving or knitting threads of yarn, but is formed by bonding fibers together through a physical means directly. Thereby, it is not possible to find any end of a thread in the textile. Nonwoven breakthroughs traditional weaving principles with the advantages of short manufacturing process, fast production speed, high throughput, low cost, wide applications, and having varied material sources. The main applications include:

-   1. Medical hygienic cloth: surgery gowns, protection clothing,     sterilized cloth, facemasks, diapers, and feminine sanitary napkins,     etc.; -   2. Domestic decorative cloth: wallpaper, tablecloths, bed sheets,     and coverlets, etc.; -   3. Backing: lining, bonding lining, flocculus, shaping cotton, and     various base cloth for synthetic leather, etc.; -   4. Industrial cloth: filtering materials, insulation materials,     packing bags for cement, earthwork cloth, and covering cloth, etc.; -   5. Agricultural cloth: agriculture mulch, cloth for raising     seedlings, irrigation cloth, and thermal insulating curtains, etc.; -   6. Others: space cotton, heat and sound insulating materials, oil     absorption felts, cigarette filters, and tea bags, etc.

Nonwoven can be classified into:

-   1. Spunlace nonwoven: Jet high-pressure minute water to a single or     multiple layered fiberweb to entangle the fibers. Thereby, the     fiberweb can be reinforced and t its strength is increased. -   2. Heat-bonded nonwoven: Add fiber-shaped or powdery heat-melt     binding and reinforcing materials to a fiberweb. Then the fiberweb     is heated and cooled to form reinforced cloth. -   3. Airlaid pulp nonwoven: The airlaid pulp nonwoven is also called     airlaid paper or drylaid nonwoven. Wood pulp fibers are loosened up     into single fibers. Next, air is applied to agglomerate the fibers     onto a web curtain. The fiberweb is then reinforced to form cloth. -   4. Wetlaid nonwoven: Fiber raw materials placed in water are     loosened up into single fibers and mixed with various fiber raw     materials to give fiber suspensions. The suspensions are delivered     to the webbing mechanism. The fibers are laid into web under wet     conditions and then reinforced to form cloth. -   5. Spunbonded nonwoven: Polymers are extruded and lengthened to form     continuous long threads, which are laid into a fiberweb. The fiber     web is then processed to form nonwoven through self-bonding,     heat-bonding, chemical bonding, or mechanical reinforcement methods. -   6. Meltblown nonwoven: Polymers are melt and extruded to form     fibers. The fibers are cooled and blown into a fiberweb. Then the     fiberweb is reinforced to form cloth. -   7. Needle-punched nonwoven: This is one kind of drylaid nonwoven.     The punching effect of needles is used to reinforce a loose     fiberweb. -   8. Stitch-bonded nonwoven: This is one kind of drylaid nonwoven. Use     warp and weft loop structures to reinforce the fiberweb, yarn layer,     non-fabric materials (such as plastic flakes, plastic foils, metal     foils, etc.) or their combinations and form nonwoven.

Accordingly, before weaving process, taking polymer material as an example, the preparation process is very complicated including synthesis, reeling, and spinning. During reeling and spinning, mechanical strength of fibers is extremely important because fibers are reeled and pulled by machines. If the mechanical strength of fibers is not enough, difficulties will result. The present invention provides a weaving method using nonwoven as the yarn, eliminating the need of considering mechanical characteristics of fibers.

SUMMARY

An objective of the present invention is to provide a weaving method using nonwoven as yarn, which can weave without the need of considering physical characteristics, such as strength and stress, of fibers.

Another objective of the present invention is to provide a weaving method using nonwoven as yarn, which can weave without the need of performing spinning process. The spinning process is replaced by the nonwoven process.

In order to achieve the objectives and effects described above, the present invention provides a weaving method using nonwoven as yarn, which discloses that nonwoven is slit first and then the slit nonwoven is used for weaving. In the weaving process, yarn with different materials can be added for producing textiles with various functionalities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a manufacturing flowchart according to a preferred embodiment of the present invention;

FIG. 2 shows a weaving flowchart according to a preferred embodiment of the present invention; and

FIG. 3 shows a manufacturing flowchart according to another preferred embodiment of the present invention.

DETAILED DESCRIPTION

In order to make the structure and characteristics as well as the effectiveness of the present invention to be further understood and recognized, the detailed description of the present invention is provided as follows along with preferred embodiments and accompanying figures.

The present invention uses nonwoven as the yarn, and weaves with itself or yarn of other materials to produce cloth.

FIG. 1 shows a manufacturing flowchart according to a preferred embodiment of the present invention. As shown in the figure, the present invention uses nonwoven as the yarn, and comprises steps of: step S10, taking nonwoven; step S12, performing slitting process on the nonwoven and obtianing a plurality of nonwoven yarn threads; step S14, performing a weaving procedure on the plurality of nonwoven yarn threads for producing cloth.

Because nonwoven has the physical characteristics of softness, using it as the yarn can increase usability of cloth. In addition, by taking advantage of the softness characteristics of nonwoven along with various weaving schemes, different appearances and applications can be provided.

The nonwoven described above is the fabrics manufactured by bonding, needle punching, water mangling, heat melting, spunbonding, and meltblowing using fabric fibers as the raw material. The nonwoven described in the present invention is not the technological characteristic of the present invention. Thereby, cloth manufactured by wetlaid, drylaid, or polymer extrusion can be used as well.

Furthermore, the weaving methods according to the present invention include tatting and knitting. Taking tatting as an example and referring to FIG. 2, the weaving method comprises the following steps. Step S20, warping: organize the yarn and install it on the beam. Step S21, sizing: the strength of yarn is not sufficient. Hence the yarn has to immerse into the thick amylum liquid. Step S22, leasing and healding: divide the threads in the beam into odd and even threads, and install them in the heald frame. Step S23: reeding: installing the heald frame to the weaving machine. Step S24, weaving: when the warp yarn is carried up or down depending on odd or even numbering, the weft yarn is carried by a shuttle back and forth to weave the two sets of yarn threads. Step S25, examination: Examine if flaws exist in the woven cloth. Mending is performed if required. Step S26, finishing: deliver the finished textile or perform further dyeing and finishing.

FIG. 3 shows a manufacturing flowchart according to another preferred embodiment of the present invention. As shown in the figure, the manufacturing process according to another preferred embodiment of the present invention comprises steps of: step S30, taking nonwoven; step S32, performing slitting process on the nonwoven and obtaining a plurality of nonwoven yarn threads; step S34, performing a weaving procedure on the plurality of nonwoven yarn threads and a thread of yarn for producing cloth.

Because yarn with different materials, which includes polymer, metal, or nonmetal materials, can be woven with the nonwoven yarn according to the present invention, textiles with various functionalities can produced. Besides, tatting or knitting can be applied during weaving.

Accordingly, the present invention conforms to the legal requirements owing to its novelty, non-obviousness, and utility. However, the foregoing description is only a preferred embodiment of the present invention, not used to limit the scope and range of the present invention. Those equivalent changes or modifications made according to the shape, structure, feature, or spirit described in the claims of the present invention are included in the appended claims of the present invention. 

1. A weaving method using nonwoven as yarn, comprising steps of: taking a nonwoven; performing slitting process on the nonwoven and obtaining a plurality of nonwoven yarn threads; and performing a weaving procedure on the plurality of nonwoven yarn threads for producing cloth.
 2. (canceled)
 3. The weaving method of claim 1, wherein the weaving procedure is tatting.
 4. The weaving method of claim 1, wherein the weaving procedure is knitting.
 5. A weaving method using nonwoven as yarn, comprising steps of: taking nonwoven; performing slitting process on the nonwoven and obtaining a plurality of nonwoven yarn threads; and performing a weaving procedure on the plurality of nonwoven yarn threads and a thread of yarn for producing cloth.
 6. (canceled)
 7. The weaving method of claim 5, wherein the weaving procedure is tatting.
 8. The weaving method of claim 5, wherein the weaving procedure is knitting.
 9. The weaving method of claim 5, wherein the thread of yarn is a polymer thread of yarn.
 10. The weaving method of claim 5, wherein the thread of yarn is a metal thread of yarn.
 11. The weaving method of claim 5, wherein the thread of yarn is a nonmetal thread of yarn. 